Installation Instructions
Santa Clara, CA 95050 © 2001 The Watt Stopper,
®
Inc.
HIO16CC
Complete Control Switch Interface Card
for Upgrading PLC Panels
The HIO16CC Switch Interface
Card is an intelligent upgrade card
for a GE Programmable Lighting
Control (PLC) panel. It provides a
path from PLC to the more fully-
featured Watt Stopper Complete
Control (CC) system architecture.
Most older GE systems fall into two
categories: ETA panels with an ECON
Controller, or SRC panels with no
central controller. (Refer to the table
“Upgrading From PLC To Complete
Control” on the next page for a
summary of system components.) To
upgrade these panels to CC, simply
replace the existing Relay Controller
and Switch Interface Cards with the
new HCPU32CC and HIO16CC
modules. Upgraded panels can
coexist with older panels until the
whole system is converted to
Complete Control.
The HIO16CC Switch Interface Card replaces the
ES8 or ES16 card in an existing ETA panel, or the
SRS16 card in an SRC panel.
The motherboard in these panels requires one
HCPU32CC Relay Controller Card to provide full
monitoring and control for up to 32 relays. The switch
interface card is optional, but if one is present in the
PLC panel, it must be upgraded to an HIO16CC at the
same time as the HCPU32CC.
The HIO16CC provides programmable switch
interface points, allowing the user to integrate the
switching functions of a Programmed System Switch
(PSS) into an existing PLC system.
Features
• Simple plug-in module
• No rewiring of switches necessary
• 16 switch inputs per panel
• Use 3-wire maintained or momentary switches
• Provides system functions for Clean, Photocell,
Blink Warn and Master Switch
Note: The original type of PLC system, a BCON
Controller with BTA panels, can also be upgraded
using an additional kit, the HEMB32CAN.
Before starting, read the instructions on the next
three pages. If you have any questions, call our
Service Team at: 888-852-2778.
ETA Panel with HCPU32CC and HIO16CC upgrade card installed
2
HIO16CC Complete Control Switch Interface Card for Upgrading PLC Panels
CAUTION: The power supply must be off when inserting or removing cards.
These instructions assume the panel has a standard cover which exposes both
line voltage and low voltage sections. The line voltage sections must be
covered to avoid exposure to live high voltage wiring.
If an SRC system is being upgraded, DO NOT CONNECT THE DATALINE UNTIL
AFTER ALL THE PANELS HAVE BEEN UPGRADED. SRC modules will fail if
connected to the dataline.
Steps for Upgrading
1 If you are upgrading a BTA/BCON
system, install the HEMB32CAN kit
(see instructions INHEMB).
2 For all systems, next install the
HCPU32CC Relay Controller Card
(see instructions INHCPU32).
3 If switch interfaces are required, next
install the HIO16CC Switch Interface
Card per instructions below).
Installing the HIO16CC
These instructions repeat several of the
steps involved in an HCPU32CC
installation. If you have just installed the
HCPU32CC and have not yet reapplied
power, skip to Step 6. Power must be off.
1 Program the system. Before
replacing any cards, you should set
up the new system program using
CC system software HSOFT-CM1 or
WinControl. Upgraded panels must
receive an initial program from the
software in order to work. To minimize
downtime for your lighting control
system, please document your site
wiring and prepare the software
program for your site before physically
changing any hardware. Refer to the
User’s Manual supplied with the
software.
2 Turn off the circuit breakers
supplying line voltage to all relays
and the transformer in the panel.
3 Remove the panel cover.
4 Test the transformer terminals with
a voltmeter to ensure power is off.
(A red LED should be on when power
is on, and off when power is off.
However, for complete safety, check
with a voltmeter).
5 Examine the panel interior to
identify the motherboard (shown in
Figure 1), relay controller card
(ER16, ER32 or SRCM-R) and switch
interface card (ES8, ES16 or SRS16).
The relay controller card will be
plugged into the left connector
(marked
RELAY MODULE CONNECTOR) on
the motherboard. The switch interface
card will be in the right connector
(marked
SWITCH MODULE CONNECTOR).
Note the address settings on each
card.
B-GENERATION E-GENERATION SRC
Controller BCON ECON SRRP-xx in each panel
Panels BTA ETA SRSP
Relay Controller Card Built-in ER16 or ER32 SRCM-R
Switch Interface Card Built-in ES8 or ES16 SRS16
Dataline Yes Yes No
To Upgrade to Replace panel interior Replace relay card Replace relay card
the Watt Stopper with HEMB32CAN. with HCPU32CC. with HCPU32CC.
Complete Control … Install HCPU32CC and Replace switch card Replace switch card
HIO16CC cards. with HIO16CC. with HIO16CC.
Install a dataline if multiple
panels will be networked.
GREY/WHITE
LABEL STRIP
(see Step #9
on page 3 in
instructions
INHCPU32)
Figure 1 – Panel Motherboard
Upgrading From PLC To Complete Control
The following chart is designed to help you identify the components of your existing
GE Programmable Lighting Control (PLC) system, and the new components required
to upgrade to The Watt Stopper Complete Control.
3
6 Remove the existing switch interface
card by pulling up the Ejector Tabs
on the corners of the board. This will
“pop” the card out of the connector
on the motherboard. Then pull the
card straight out.
7 Inspect the pins in the switch
module connector on the mother-
board to ensure there are no broken
or bent pins. If any are bent, carefully
straighten them using pliers, or call
The Watt Stopper Service to replace
the motherboard.
8 Set the address of the HIO16CC
card by turning the Address Set
Knobs to the required numbers. You
should set the same address that the
old card had.
9 Slide the HIO16CC card vertically
into its slots until it rests gently on the
relay module connector pins. Make
sure the pins are properly aligned
and push the card straight in until it is
fully seated on the motherboard (you
should feel a noticeable “click”).
10 If you have maintained switches,
you must jumper red to black at the
switch input connectors.
11 Turn on the circuit breaker supplying
power to the transformer only.
12 Test the HIO16CC, using HSOFT-CM1
in the Dataline Monitor Mode (see
next page).
13 Replace the enclosure cover.
14 Turn on the circuit breakers to
restore power to the relays.
Troubleshooting
If no switches respond to the test in Step
12 above (as described in detail on the
next page), check the HIO16CC Hardware
Status LED with the low-voltage power
supply on.
If the LED is off, power is not flowing to
the card. Turn off the low-voltage power
supply and reseat the card.
If the LED is flashing, the card is
defective. Call 888-852-2778 for Service.
Figure 2 – HIO16CC Switch Interface Card
TOP OF CARD
BOTTOM OF CARD
CARD CONNECTOR
EJECTOR TAB
EJECTOR TAB
HARDWARE
STATUS LED
ADDRESS
SET KNOBS
HIO16CC Complete Control Switch Interface Card for Upgrading PLC Panels
Panel Division 888-852-2778 INHIO16 090701
Document the Site Wiring
In a networked lighting control system,
each relay panel must have a unique
address number. For CC upgrades, this
is set by the Address Set Knobs on the
HCPU32CC Relay Controller Card and
the HIO16CC Switch Interface Card.
Why do relay and switch input numbers
change when PLC is upgraded to CC?
In PLC panels, relays were set up in
groups of 16 (and switch inputs in groups
of 8) as shown in Figure 3. The first 16
relays (and 8 switch inputs) were installed
on the RIGHT side of the panel and
numbered 1-16 (1-8). Panel addresses
were usually assigned as EVEN numbers
(Panel 002, 004, etc.). If a panel included
another 16 relays (for a total of 32), and
another 8 switch inputs (for a total of 16),
they were installed on the LEFT side of
the panel, but still numbered 1-16 (1-8).
This second group of relays and switch
inputs was considered another panel,
and was assigned the next higher ODD
number panel address. So a single tub
could include two panel addresses —
Panel 002 for the RIGHT side and Panel
003 for the LEFT side.
When PLC panels are upgraded to CC,
they can still have up to 32 relays and 16
switch inputs, but only one panel address
(which can be either odd or even) as
shown in Figure 4. Relays are numbered
1-16 on the RIGHT side and 17-32 on
the LEFT side. Switch inputs are numbered
1-8 on the RIGHT side and 9-16 on the
LEFT side. Label strips are supplied with
the HCPU32CC upgrade kit to identify
the new numbering scheme (see Steps
8 and 9 on the previous page).
When documenting your site wiring and
entering this information in HSOFT-CM1
or WinControl, review the panel addresses
to ensure there are no duplicates.
Remember that panels now have one
address for both right and left sides, and
relays are now numbered 1-32 and
switch inputs 1-16.
1
8
1
16
1
8
1
16
PANEL 003
SWITCH
INPUTS
PANEL 003
RELAYS
PANEL 002
SWITCH
INPUTS
PANEL 002
RELAYS
PANEL 003 PANEL 002
Figure 3 – PLC Panel
9
16
17
32
1
8
1
16
PANEL SWITCH INPUTS
PANEL RELAYS
PANEL 002 (or 003)
Figure 4 – Upgraded PLC Panel
HIO16CC Complete Control Switch Interface Card for Upgrading PLC Panels
Testing the System
With HSOFT-CM1 Software
Use HSOFT-CM1 in the Dataline Monitor
Mode.
1 If your computer is not connected,
select the “Connect” option to connect
to the LCP or HLINKCC device.
2 From the Main Menu, select “Monitor
and Control”.
3 From the Monitor and Control Menu,
select “Monitor Dataline”.
4 You can monitor the response of
programmable system switches one of
two ways:
a) Be in contact with a second person
at the panel to be tested while you
monitor the computer, or
b) Set up a printer to capture the
response of each switch as it is tested.
If you have a parallel printer con-
nected to the computer, simply hit the
F5 key to capture each step of the test
to the printer.
5 While watching the switch status on
the Monitor Dataline screen, physically
touch the numbered switch inputs on
the motherboard with a probe. For
each switch input, touch white
(common) to red for on, and white to
black for off.
6 Status will be indicated at the bottom
of the screen in the PSS line. For
example, “PSS – 12/1 ON” says that in
Panel 012, Input 1, the PSS is on..
If any of the switches do not respond to
the test, call Service at 888-852-2778.
With WinControl
™
Software
Use WinControl in Monitor Dataline
Mode.
1 From the WinControl Menu, select
MonitorControl, then Monitor Dataline.
2 If your computer is not connected, you
will be asked if you want to connect.
Select Yes.
3 The Monitor Dataline window will
appear.
4 Physically touch the numbered switch
inputs on the motherboard with a
probe. For each switch input, touch
white (common) to red for on, and
white to black for off.
5 The activation of each switch will be
indicated in the window for each PSS
that is probed. For example, “PSS 12/1
ON” says that in Panel 12, Input 1, the
PSS is on. Ascroll bar will appear if
there is too much activity to display in
the window.
If any of the switches do not respond to
the test, call Service at 888-852-2778.
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